Forming a thrust reverser cascade using corrugated bodies

ABSTRACT

A manufacturing process is provided during which a thrust reverser cascade is formed for an aircraft propulsion system. During the formation of the thrust reverser cascade, a first panel of material is stamped into a first corrugated body. A second panel of material is stamped into a second corrugated body. The first corrugated body is bonded to the second corrugated body.

This application is a continuation of U.S. patent application Ser. No.16/404,363 filed May 6, 2019 which is hereby incorporated herein byreference in its entirety.

BACKGROUND 1. Technical Field

This disclosure relates generally to a thrust reverser for an aircraftpropulsion system and, more particularly, to methods for forming acascade for the thrust reverser.

2. Background Information

An aircraft propulsion system may include a thrust reverser forredirecting bypass air in a forward direction to generate reversethrust. Several types of thrust reversers are known in the art. Many ofthese thrust reversers include one or more arrays of cascades. Eachcascade typically includes a series of aerodynamic vanes for redirectingbypass air in a desired forward direction during reverse thrustoperation.

A composite cascade may be manufactured using a closed-die or autoclavemolding process. For example, carbon fiber fabric is laid-up in a moldaround mandrels that define open passageways of the cascade. The layupprocess is generally done by hand and is labor intensive. After thislayup, the mold is closed and compressed to consolidate the fabriclayers. The process may be expensive, difficult and time consuming.

There is a need in the art for improved processes for manufacturing athrust reverser cascade, particularly those made from fiber-reinforcedcomposite material.

SUMMARY OF THE DISCLOSURE

According to an aspect of the present disclosure, a manufacturingprocess is provided during which a thrust reverser cascade is formed foran aircraft propulsion system. During the formation of the thrustreverser cascade, a first panel of material is stamped into a firstcorrugated body. A second panel of material is stamped into a secondcorrugated body. The first corrugated body is bonded to the secondcorrugated body.

According to another aspect of the present disclosure, anothermanufacturing process is provided during which a thrust reverser cascadeis formed for an aircraft propulsion system. During the formation of thethrust reverser cascade, a first panel of material is formed into afirst corrugated body with a plurality of first peaks. A second panel ofmaterial is formed into a second corrugated body with a plurality ofsecond peaks. Each of the plurality of first peaks is bonded to arespective one of the plurality of second peaks.

According to still another aspect of the present disclosure, anothermanufacturing process is provided during which a thrust reverser cascadeis formed for an aircraft propulsion system. During the formation of thethrust reverser cascade, a plurality of panels are stamped respectivelyinto a plurality of corrugated bodies. The plurality of corrugatedbodies are arranged side-by-side in an array. The arranged plurality ofcorrugated bodies are respectively bonded together.

The thrust reverser cascade may be configured from or otherwise includefiber reinforcement within a polymer matrix.

The first panel of material may be configured from or otherwise includepolymer material.

The first panel of material may be a fiber-reinforced thermoplasticpanel of material.

The bonding of the first corrugated body to the second corrugated bodymay include bonding a first peak of the first corrugated body to asecond peak of the second corrugated body.

The first peak may be configured with a first chamfered edge.

The second peak may be configured with a second chamfered edge. Thesecond chamfered edge may be bonded to the first chamfered edge.

The first corrugated body may include a radiused interior cornerpositioned opposite the first peak.

The thrust reverser cascade may include a first rail, a second rail anda plurality of vanes connected to and extending between the first railand the second rail. The first corrugated body may be configured as orotherwise include a first corrugation. A first section of the firstcorrugation may form a first of the plurality of vanes. A second sectionof the first corrugation may form a first portion of the first rail.

The first corrugated body may also include a second corrugation. Asection of the second corrugation may form a first portion of the secondrail.

The second corrugated body may be configured as or otherwise include asecond corrugation. A first section of the second corrugation may form asecond of the plurality of vanes that is spaced from the first of theplurality of vanes by an air channel. A second section of the secondcorrugation may form a second portion of the first rail that is adjacentand connected to the first portion of the first rail.

The forming of the thrust reverser cascade may also include bonding athird panel of material to the first corrugated body and the secondcorrugated body. The third panel of material may at least partially forman exterior sidewall of the thrust reverser cascade.

The first panel of material may be configured with a continuous lengthof fiber reinforcement that extends end-to-end through the first panelof material.

The thrust reverser cascade may include a first rail, a second rail anda plurality of vanes connected to and extending between the first railand the second rail. Each of the bonded and arranged plurality ofcorrugated bodies may form a respective portion of the first rail, arespective portion of the second rail and a respective one of theplurality of vanes.

The forming of the thrust reverser cascade may also include bonding aflat panel of material to each of the plurality of corrugated bodies.The flat panel of material may at least partially form an exteriorsidewall of the thrust reverser cascade.

A first of the plurality of panel may be configured with a continuouslength of fiber that extends at least substantially along an entirelength of the first of the plurality of panels.

Each of the plurality of panels may be a fiber-reinforced thermoplasticpanel of material.

The respective bonding of the arranged plurality of corrugated bodiesmay include bonding a first peak of a first of the plurality ofcorrugated bodies to a second peak of a second of the plurality ofcorrugated bodies.

The foregoing features and the operation of the invention will becomemore apparent in light of the following description and the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective illustration of an aircraft propulsion systemwith its thrust reverser in a deployed configuration.

FIG. 2 is a side sectional illustration of an aft portion of theaircraft propulsion system with its thrust reverser in a stowedconfiguration.

FIG. 3 is a side sectional illustration of the aft portion of theaircraft propulsion system with its thrust reverser in the deployedconfiguration.

FIG. 4 is another perspective illustration of the aircraft propulsionsystem with its thrust reverser in the deployed configuration as well asexemplary flowpaths of air directed out of the thrust reverser.

FIG. 5 is a perspective illustration of an embodiment thrust reversercascade for the thrust reverser.

FIG. 6 is a cross-sectional illustration of a portion of an embodimentof the thrust reverser cascade.

FIG. 7 is a cross-sectional illustration of a portion of anotherembodiment of the thrust reverser cascade.

FIG. 8 is a side sectional illustration of a portion of an embodiment ofthe thrust reverser cascade.

FIG. 9 is a side sectional illustration of a portion of anotherembodiment of the thrust reverser cascade.

FIG. 10 is a block diagram of a process for forming a thrust reversercascade.

FIG. 11 is a block diagram of a process for forming a cascade structure.

FIG. 12 is a perspective schematic illustration of a panel of material.

FIG. 13 is a schematic illustration of a corrugated body.

FIG. 14 is a schematic illustration of another corrugated body.

FIG. 15 is a schematic illustration of a corrugated body structure.

FIG. 16 is a sectional illustration of an exemplary bond joint for thecorrugated body structure.

FIG. 17 is a schematic illustration of the cascade structure.

DETAILED DESCRIPTION

The present disclosure includes methods for manufacturing one or morecascades for a thrust reverser of an aircraft propulsion system. Thisaircraft propulsion system includes and is powered by a gas turbineengine such as, but not limited to, a turbofan gas turbine engine or aturbojet gas turbine engine. An exemplary embodiment of such an aircraftpropulsion system 20 and such a thrust reverser 22 is illustrated inFIG. 1. For ease of description, the methods of the present disclosuremay be described below with reference to the exemplary aircraftpropulsion system 20 and thrust reverser 22 of FIG. 1. The methods ofthe present disclosure, however, may also be performed to manufacturethrust reverser cascades for different aircraft propulsion systems andcascades of different types and configurations other than thosedescribed below and illustrated in the drawings.

The propulsion system 20 of FIG. 1 includes an outer (e.g., fan/bypass)nacelle structure 24 and an inner (e.g., core) nacelle structure 25 (seeFIGS. 2 and 3). This inner nacelle structure 25 may be referred to as an“inner fixed structure” or an “IFS”. Referring to FIGS. 2 and 3, theinner nacelle structure 25 houses and is configured to provide anaerodynamic cover for a core of the gas turbine engine. Briefly, theengine core may include a compressor section, a combustion section and aturbine section of the gas turbine engine.

Referring again to FIG. 1, the outer nacelle structure 24 includes astationary forward module 26, which may include a nacelle inlet 28 and afan cowling 30. The outer nacelle structure 24 also includes an aftthrust reverser module 32. This thrust reverser module 32 includes atranslating sleeve 34 and a thrust reverser cascade array 36. Referringto FIGS. 2 and 3, the thrust reverser module 32 may also include one ormore blocker doors 38 configured to deploy and direct air from a bypassflowpath 40 of the aircraft propulsion system 20 into the cascade array36 during thrust reverser 22 deployment.

The translating sleeve 34 is configured to translate axially aft alongan axial centerline 42 of the propulsion system 20 in order to exposethe cascade array 36 and open a thrust reverser flowpath 44 (see FIG.3). This thrust reverser flowpath 44 receives bypass air from the bypassflowpath 40, and directs this air through the cascade array 36 whichredirects that air in a radially outward and axially forward direction.The cascade array 36 may also redirect the air in a circumferentialdirection in order to, for example, direct the air away from a runwayand/or wings of an aircraft as illustrated in FIG. 4. The translatingsleeve 34 is also configured to translate axially forward along thecenterline 42 in order to cover the cascade array 36 and close thethrust reverser flowpath 44 (see FIG. 2).

Referring again to FIG. 1, the cascade array 36 may include one or moresub-arrays 46. The cascade array 36 of FIG. 1, for example, includefirst and second sub-arrays 46, where the second sub-array 46B issubstantially diametrically opposed from the first sub-array 46A andtherefore hidden in FIG. 1. Each of these sub-arrays 46 includes one ormore thrust reverser cascades 48 arranged circumferentially around thecenterline 42.

FIG. 5 illustrates an exemplary one of the thrust reverser cascades 48.This cascade 48 extends longitudinally (e.g., along an x-axis andgenerally parallel with the centerline 42) between opposing cascade ends50 and 52. The cascade 48 extends laterally (e.g., along a y-axis andgenerally circumferentially around or tangent to the centerline 42)between opposing cascade sides 54 and 56. The cascade 48 also extendstransversely (e.g., along a z-axis and generally radially relative tothe centerline 42) between opposing inner and outer sides 58 and 60.

The cascade 48 of FIG. 5 includes a base cascade structure 62 and one ormore attachments 64 and 66; e.g., mounting structures. Each of theseattachments 64 and 66 is configured to attach/mount the cascadestructure 62 to another structure of the propulsion system 20 such as,but not limited to, a torque box 68 or an aft cascade ring 70 (see FIGS.2 and 3). The attachments 64 and 66 of FIG. 5, for example, areconfigured as attachment flanges with apertures for receiving fasteners;e.g., bolds, rivets, etc.

The cascade structure 62 includes a plurality of strongback rails 72 andone or more arrays 74 of cascade vanes 76. The strongback rails 72 ofFIG. 5 are arranged parallel with one another, and extend longitudinallybetween the cascade ends 50 and 52. One or more of the strongback rails72 (e.g., the laterally exterior rails) may extend into and/or may beconfigured with one or more of the attachments 64 and 66. One or more ofthe strongback rails 72 (e.g., the laterally interior rails) may extendto one or more of the attachments 64 and 66. Referring to FIG. 6, eachof the strongback rails 72 may have a non-linear (e.g., curved)cross-sectional geometry in order to redirect air flowing through thecascade 48 in the circumferential direction. Alternatively, referring toFIG. 7, one or more of the strongback rails 72 may each have a linear(e.g., straight) cross-sectional geometry.

Referring again to FIG. 5, the arrays 74 of cascade vanes 76 arerespectively arranged between laterally adjacent strongback rails 72.Each of the arrays 74 of cascade vanes 76 includes a plurality of thecascade vanes 76, which are disposed at discrete locations along thelongitudinally length of the strongback rails 72. Each longitudinallyadjacent pair of vanes 76 thereby forms an air channel 77 therebetween.Each of the cascade vanes 76 extends laterally between and is connectedto (e.g., bonded to or formed integral with) a respective adjacent setof the strongback rails 72. Referring to FIG. 8, each of the cascadevanes 76 may have a non-linear (e.g., curved) cross-sectional geometryin order to redirect air flowing through the cascade 48 in the axialdirection. Alternatively, referring to FIG. 9, one or more of thecascade vanes 76 may each have a linear (e.g., straight) cross-sectionalgeometry.

As described below in further detail, the entire cascade 48 or at leasta portion thereof may be composed of composite material; e.g.,fiber-reinforced composite material. For example, the cascade 48 may beformed using fiber reinforcement within a polymer matrix; e.g.,thermoplastic material. Examples of the fiber reinforcement materialinclude, but are not limited to, fiberglass material, carbon fibermaterial, fiberglass, and/or aramid (e.g., Kevlar®) material. The fibermaterial may include one or more continuous lengths of fiber asdiscussed below in further detail. The present disclosure, however, isnot limited to the foregoing exemplary materials. Each cascade 48, forexample, may be formed from any material capable of being processed asdescribed below.

FIG. 10 is a flow diagram of a process 1000 for forming a thrustreverser cascade. This process 1000 is described below with reference toforming the thrust reverser cascade 48 for ease of description. Theprocess 1000 of FIG. 10, however, may alternatively be used to formthrust reverser cascades other than the one described above.

In step 1002, the cascade structure 62 is formed. This cascade structure62 may be formed using, for example, a sub-process 1100 as illustratedin FIG. 11.

In step 1102, a plurality of panels (e.g., strips) of material 78 areprovided, an exemplary one of which is illustrated in FIG. 12. Each ofthese panels of material 78 may be configured as a fiber-reinforcedpolymer (e.g., thermoplastic) panel of material. In some embodiments,each panel of material 78 may include one or more continuous (e.g.,uninterrupted) lengths of fiber reinforcement that extend end-to-endthrough the respective panel of material 78. For example, the panel ofmaterial 78 of FIG. 12 is configured with one or more continuous fibers80, where each continuous fiber 80 is embedded with within a polymer(e.g., thermoplastic) matrix 82 and extends at least substantially(e.g., at least 95%) or completely along an entire length 84 of thepanel of material 78. Of course, in other embodiments, a single fiber 80may extend back and forth one or more times at least substantially alongthe entire length 84 of the panel of material.

In step 1104, each of the panels of material 78 is formed into acorrugated body 86; e.g., see FIG. 13. For example, each panel ofmaterial 78 may be stamped into the corrugated body 86. The corrugatedbody 86 includes one or more corrugations 88 arranged end-to-end along alength thereof. Each corrugation 88 includes a first section 90 and asecond section 92. A first end of the first section 90 meets and isconnected to a first end of the second section 92 at anintra-corrugation peak 94 (e.g., a corner) of the corrugation 88. Asecond end of the first section 90 may meet and be connected to a secondend of the second section 92 of an adjacent corrugation 88 at aninter-corrugation peak 96 (e.g., a corner) between the respectivecorrugations 88. Similarly, the second end of the second section 92 maymeet and be connected to the second end of the first section 90 ofanother adjacent corrugation 88 at another inter-corrugation peak 96between the respective corrugations 88. With such a configuration, thecorrugated body 86 has a stepped (e.g., zig-zagged) configuration whereeach of the first sections 90 may form a riser section and each of thesecond sections 92 may form a run section, or vice versa depending uponthe orientation of the corrugated body 86.

In some embodiments, each peak 94 and/or 96 of the corrugated body 86may have a sharp edge as shown in FIG. 13. However, in otherembodiments, at least one or each peak 94 and/or at least one or eachpeak 96 of the corrugated body 86 may have a chamfered edge as shown inFIG. 14.

Referring again to FIG. 13, opposite each intra-corrugation peak 94 isan intra-corrugation interior corner 98 and opposite eachinter-corrugation peak 96 is an inter-corrugation interior corner 100.Each of these corners 98 and/or 100 of the corrugated body 86 may beconfigured as a sharp (e.g., a squared-off) corner as shown in FIG. 13.However, in other embodiments, at least one or each corner 98 and/or atleast one or each corner 100 of the corrugated body 86 may be configuredas a radiused (e.g., curved, arcuate) or filleted corner as shown inFIG. 14.

In step 1106, the corrugated bodies 86 are arranged side-by-side in anarray 102 as shown, for example, in FIG. 15. In this array 102, eachintra-corrugation peak 94 of each corrugated body 86 is aligned with andmay engage (e.g., contact) a respective inter-corrugation peak 96 of anadjacent one of the corrugated bodies 86. In addition or alternatively,each inter-corrugation peak 96 of each corrugated body 86 is alignedwith and may engage (e.g., contact) a respective intra-corrugation peak94 of another adjacent one of the corrugated bodies 86. Note, thechamfered edges provide additional contact area between the alignedpeaks 94 and 96 for subsequent bonding; e.g., see FIG. 16.

In step 1108, the array of the corrugated bodies 86 are bonded together.For example, the aligned peaks 94 and 96 between adjacent corrugatedbodies 86 may be welded, adhered and/or otherwise bonded together toprovide a corrugated body structure 104.

In step 1110, at least a portion (or an entirety) of a perimeter of thecorrugated body structure 104 is reinforced. For example, at least oneadditional panel of material 106 (similar to or the same as the panelsof material 78; see FIG. 12) is arranged along the perimeter of thecorrugated body structure 104 as shown, for example, in FIG. 17. Eachpanel of material 106 may extend along an entire side as shown in FIG.17. Alternatively, a respective panel of material 106 may extendpartially along a respective side. Still alternatively, a respectivepanel of material 106 may extend along some or all of the sides of thecorrugated body structure 104; e.g., wrap partially or completely aroundthe structure 104. Each additional panel of material 106 is subsequentlybonded to the corrugated body structure 104 to provide the cascadestructure 62.

With the formation process 1100 of FIG. 11, each first section 90 ofeach corrugated body 86 may (e.g., completely) form a respective one ofthe vanes 76, or partially form a respective portion of a respective oneof the endwalls 108. Each second section 92 of each corrugated body 86may (e.g., completely) form a respective portion of a respective one ofthe interior strongback rails 72, or partially form a respective portionof a respective one of the exterior strongback rails 72. Each additionalpanel of material 106 may similarly at least partially form a perimeterwall section (e.g., an exterior sidewall) of the cascade structure 62such as, for example, a respective exterior strongback rail 72 or arespective endwall 108. Thus, each vane 76 may be defined by a singlefirst section 90 whereas each strongback rail 72 may be defined by atleast a longitudinal array of end-to-end second sections 92.

Referring again to the process 1000 of FIG. 10, in step 1004, one ormore of the attachments 64 and 66 are formed; e.g., see FIG. 5. One ormore of the attachments 64 and 66 may be formed from a polymer such asthermoplastic material with or without fiber-reinforcement. The entirecascade 48 may thereby be formed of the same or similar material; e.g.,fiber-reinforce polymer (e.g., thermoplastic) material.

In step 1006, the attachments 64 and 66 are bonded to the cascadestructure 62 to thereby form the cascade 48; e.g., see FIG. 5. Eachattachment 64, 66, for example, may be bonded to a respective end 50, 52of the cascade structure 62 using any suitable bonding technique. Suchbonding techniques include, but are not limited to, ultrasonic welding,resistance welding, adhesion, etc. Of course, in other embodiments, oneor more of the attachments 64 and 66 may be formed along with thecascade structure 62 during the formation step such that theattachment(s) 64, 66 is/are formed integrally with the cascade structure62.

Using the processes of FIGS. 10 and 11, the manufacture of the cascade48 may be at least partially automated and reduce or eliminaterequirements for hand layup techniques. For example, the panels ofmaterial may be cut to length and then stamped using automatedequipment.

While various embodiments of the present invention have been disclosed,it will be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible within the scope of theinvention. For example, the present invention as described hereinincludes several aspects and embodiments that include particularfeatures. Although these features may be described individually, it iswithin the scope of the present invention that some or all of thesefeatures may be combined with any one of the aspects and remain withinthe scope of the invention. Accordingly, the present invention is not tobe restricted except in light of the attached claims and theirequivalents.

What is claimed is:
 1. A manufacturing process, comprising: forming athrust reverser cascade of an aircraft propulsion system, the forming ofthe thrust reverser cascade comprising forming a first panel of materialinto a first corrugated body, wherein the first corrugated bodycomprises a first corrugated body first section and a first corrugatedbody second section that meets and is connected to the first corrugatedbody first section at a first corner; forming a second panel of materialinto a second corrugated body, wherein the second corrugated bodycomprises a second corrugated body first section and a second corrugatedbody second section that meets and is connected to the second corrugatedbody first section at a second corner; and bonding the first corrugatedbody to the second corrugated body, wherein the first corner is abuttedagainst the second corner; wherein the thrust reverser cascade includesa first rail, a second rail and a plurality of vanes connected to andextending between the first rail and the second rail; wherein the firstcorrugated body comprises a first corrugation; wherein a first sectionof the first corrugation forms a first of the plurality of vanes, and asecond section of the first corrugation forms a first portion of thefirst rail; wherein the second corrugated body comprises a secondcorrugation; and wherein a first section of the second corrugation formsa second of the plurality of vanes that is spaced from the first of theplurality of vanes by an air channel, and a second section of the secondcorrugation forms a second portion of the first rail that is in linewith the first portion of the first rail.
 2. The manufacturing processof claim 1, wherein the first panel of material comprises polymermaterial.
 3. The manufacturing process of claim 1, wherein the firstpanel of material comprises a fiber-reinforced thermoplastic panel ofmaterial.
 4. The manufacturing process of claim 1, wherein the firstcorner is configured with a first chamfered edge.
 5. The manufacturingprocess of claim 4, wherein the second corner is configured with asecond chamfered edge; and the second chamfered edge is bonded to thefirst chamfered edge.
 6. The manufacturing process of claim 1, whereinthe first corrugated body includes a radiused interior corner positionedopposite the first corner.
 7. The manufacturing process of claim 1,wherein the first corrugated body further comprises a secondcorrugation; and a section of the second corrugation forms a firstportion of the second rail.
 8. The manufacturing process of claim 1,wherein the forming of the thrust reverser cascade further comprisesbonding a third panel of material to the first corrugated body and thesecond corrugated body; and the third panel of material at leastpartially forms an exterior sidewall of the thrust reverser cascade. 9.The manufacturing process of claim 1, wherein the first panel ofmaterial is configured with a continuous length of fiber reinforcementthat extends end-to-end through the first panel of material.
 10. Amanufacturing process, comprising: forming a thrust reverser cascade ofan aircraft propulsion system, the thrust reverser cascade comprising afirst rail, a second rail, a third rail, a plurality of first vanes anda plurality of second vanes, the plurality of first vanes connected toand extending laterally between the first rail and the second rail, theplurality of second vanes connected to and extending laterally betweenthe second rail and the third rail, and the forming of the thrustreverser cascade comprising forming a first panel of material into afirst corrugated body, the first corrugated body comprising a firstcorrugated body first section and a first corrugated body second sectionthat meets and is connected to the first corrugated body first sectionat a first corner; forming a second panel of material into a secondcorrugated body, the second corrugated body comprising a secondcorrugated body first section and a second corrugated body secondsection that meets and is connected to the second corrugated body firstsection at a second corner; and bonding the first corrugated body to thesecond corrugated body, the first corner abutted against the secondcorner; wherein the first corrugated body first section forms a firstportion of the second rail, and the first corrugated body second sectionforms a first of the plurality of first vanes; and wherein the secondcorrugated body first section forms a second portion of the second rail,and the second corrugated body second section forms a first of theplurality of second vanes.
 11. The manufacturing process of claim 10,wherein the first of the plurality of first vanes is longitudinallyaligned with the first of the plurality of second vanes.
 12. Themanufacturing process of claim 10, wherein the first of the plurality offirst vanes is parallel with the first of the plurality of second vanes.13. The manufacturing process of claim 10, wherein the first portion ofthe second rail is laterally aligned with the second portion of thesecond rail.
 14. The manufacturing process of claim 10, wherein thefirst portion of the second rail is coaxial with the second portion ofthe second rail.
 15. The manufacturing process of claim 10, wherein thefirst portion of the second rail is adjacent and connected to the secondportion of the second rail.
 16. The manufacturing process of claim 10,wherein the first panel of material comprises polymer material.
 17. Themanufacturing process of claim 10, wherein the first panel of materialcomprises a fiber-reinforced thermoplastic panel of material.
 18. Themanufacturing process of claim 10, wherein the first corner isconfigured with a first chamfered edge; the second corner is configuredwith a second chamfered edge; and the bonding comprising bonding thesecond chamfered edge to the first chamfered edge.
 19. The manufacturingprocess of claim 10, wherein the first panel of material is configuredwith a continuous length of fiber reinforcement that extends end-to-endthrough the first panel of material.
 20. A manufacturing process,comprising: forming a thrust reverser cascade of an aircraft propulsionsystem, the thrust reverser cascade comprising a first rail, a secondrail, a third rail, a plurality of first vanes and a plurality of secondvanes, the plurality of first vanes connected to and extending laterallybetween the first rail and the second rail, the plurality of secondvanes connected to and extending laterally between the second rail andthe third rail, and the forming of the thrust reverser cascadecomprising forming a first panel of material into a first corrugatedbody with a plurality of first corrugations, a first of the plurality offirst corrugations comprising a first corrugation first section and afirst corrugation second section that meets and is connected to thefirst corrugation first section at a first corner; forming a secondpanel of material into a second corrugated body with a plurality ofsecond corrugations, a first of the plurality of second corrugationscomprising a second corrugation first section and a second corrugationsecond section that meets and is connected to the second corrugationfirst section at a second corner; and bonding the first corrugated bodyto the second corrugated body, the first corner contacting the secondcorner; wherein the first corrugation first section forms a firstportion of the second rail, and the first corrugation second sectionforms a first of the plurality of first vanes; and wherein the secondcorrugation first section forms a second portion of the second rail, andthe second corrugation first section forms a first of the plurality ofsecond vanes.